Rear impact guard

ABSTRACT

A rear impact guard configured to be coupled to a rear end of a trailer includes (i) a bumper support member having an upper end configured to be coupled to the rear end of the trailer, and (ii) a horizontal bumper mounted at a lower end of the bumper support member. The bumper support member includes a hollow, generally triangular prism member.

This application claims priority to and the benefit of U.S. ProvisionalPatent Application Ser. No. 61/951,080 filed Mar. 11, 2014, and furtherclaims priority to and the benefit of U.S. Provisional PatentApplication Ser. No. 62/039,546 filed Aug. 20, 2014, each of theforegoing applications titled REAR IMPACT GUARD.

FIELD OF THE INVENTION

The present invention relates generally to semi-trailers, such asvan-type trailers, for example. In particular, the present inventionrelates to a rear impact guard for a semi-trailer.

BACKGROUND OF THE INVENTION

The rear impact guard of a trailer, semi-trailer, and/or flatbed traileris generally provided to help prevent other vehicles in a rear-impactcollision with such a trailer from traveling beyond the rear extremityof the trailer and into an area beneath the floor assembly of thetrailer. Rear impact guards may also operate to absorb the energy of arear impact from another vehicle. Rear impact guards typically include ahorizontal member suspended from two struts attached to the bottom sideof the trailer rear end wall.

SUMMARY

The present invention may comprise one or more of the features recitedin the attached claims, and/or one or more of the following features andcombinations thereof.

According to one aspect of the present disclosure, a rear impact guardconfigured to be coupled to a rear end of a trailer includes a bumpersupport member configured to be coupled to the rear end of the trailerand a horizontal bumper mounted at a lower end of the bumper supportmember. The bumper support member includes a hollow, generallytriangular prism member.

In one illustrative embodiment, the triangular hollow prism member mayinclude first and second generally triangle-shaped faces, a verticalmember or side, a horizontal member or side, and an angled member orside. Illustratively, the vertical, horizontal and angled members mayeach be positioned between and coupled to outer edges of the first andsecond triangular-shaped faces.

Each triangular-shaped face may include a first bottom edge and thevertical member may include a second bottom edge generally perpendicularto the first bottom edge. Illustratively, a top surface of thehorizontal bumper may be coupled to the first and second bottom edges ofthe triangular hollow prism member. Further illustratively, eachtriangular-shaped face may include a generally triangular-shapedaperture. The horizontal member and the angled member may each includean aperture.

Illustratively, the vertical member may extend vertically above thehorizontal member.

Further illustratively, an angle between the vertical member and eachtriangular-shaped face may be less than 90 degrees. In particular, theillustrative angle may be approximately 87 degrees. Illustratively, afirst distance between a forward-most portion of each triangular-shapedface may be less than a second distance between outer edges of thehorizontal member.

Illustratively, the first triangular-shaped face, the secondtriangular-shaped face, and the vertical member may cooperate to definea one-piece component. The horizontal member and the angled member mayalso cooperate to define a one-piece component.

Further illustratively, a bottom edge of the angled member may becoupled to a front wall of the horizontal bumper.

Illustratively, the angled member may include a central body having anupper edge coupled to the horizontal member, a lower edge coupled to thehorizontal bumper, a first side edge coupled to the firsttriangular-shaped face and a second side edge coupled to the secondtriangular-shaped face. The angled member may further include a firstflange coupled to the first edge and configured to extend forward of thefirst edge away from the first triangular-shaped face, and a secondflange coupled to the second edge and configured to extend forward ofthe second edge away from the second triangular-shaped face.

Further illustratively, a bottom edge of the angled member and a bottomedge of the vertical member may be spaced apart from each other.

Illustratively, the triangular hollow prism member may be oriented suchthat the vertical member extends upwardly from the horizontal tube andthe horizontal member of the triangular hollow prism member is coupledto and extends away from an upper portion of the vertical member at agenerally perpendicular angle.

In another illustrative embodiment, the horizontal bumper may begenerally tube-shaped.

In yet another illustrative embodiment, the bumper support member may bea first bumper support member. Illustratively, the rear impact guard mayfurther include a second bumper support member spaced-apart from thefirst bumper support member. Further illustratively, the rear impactguard may also include a third bumper support member and a fourth bumpersupport member. The first and third bumper support members may bepositioned to the left of a longitudinal axis of the trailer and thesecond and fourth bumper support members may be positioned to the rightof a longitudinal axis of the trailer when viewed from the rear.Illustratively, the third and fourth bumper support members may bepositioned near the respective outermost ends of the horizontal bumper.

According to another aspect of the present disclosure, a rear impactguard configured to be coupled to a rear end of a trailer includes abumper support member configured to be coupled to the rear end of thetrailer and a horizontal bumper mounted at a lower end of the bumpersupport member. The bumper support member includes a first face, asecond face spaced-apart from the first face, and a vertical memberpositioned between and coupled to the first and second faces.

In one illustrative embodiment, a lower edge of the vertical member anda lower edge of each of the first and second faces may be coupled to thehorizontal bumper.

In another illustrative embodiment, the first face and the second facemay be angled relative to each other. Illustratively, a first end ofeach of the first and second faces is coupled to the vertical member,and the first ends may be spaced-apart from each other a first distance.A second end of each of the first and second faces may be spaced-apartfrom each other a second distance that may be smaller than the firstdistance.

In still another illustrative embodiment, the bumper support member mayalso include a generally horizontal member coupled to the verticalmember and coupled to and positioned between the first and second faces.

According to another aspect of the present disclosure, a rear impactguard configured to be coupled to a rear end of a trailer includes abumper support member configured to be coupled to the rear end of thetrailer, a horizontal bumper mounted at a lower end of the bumpersupport member, and a gusset coupled to the horizontal bumper and anouter end of the bumper support member. The gusset is generallytriangular in shape, and the bumper support member includes a hollow,generally triangular prism member.

In one illustrative embodiment, the gusset may include a top edge thatis generally Z-shaped. Illustratively, a length of the bottom edge ofthe gusset may be shorter than a length of the top edge of the gusset.Further illustratively, the gusset may include a triangular wall, amiddle wall at a 90 degree angle to the triangular wall, and an end wallat a 90 degree angle to the middle wall such that the end wall and thetriangular wall are parallel to each other. The end wall may be aparallelogram. Illustratively, the triangular wall may be a right-sidedtriangle and a vertical, side edge of the triangular wall may be coupledto the bumper support member and a bottom edge of the triangular wallmay be coupled to the horizontal bumper.

In another illustrative embodiment, the gusset may include a legconfigured to extend downwardly over and be coupled to a front wall ofthe bumper support member. Illustratively, a bottom edge of the leg maybe positioned approximately mid-way along a height of a front wall ofthe horizontal bumper. Alternatively, the bottom edge of the leg may bepositioned collinear with a bottom edge of a front wall of thehorizontal bumper.

In still another illustrative embodiment, the rear impact guard may alsoinclude a gusset attachment coupled to a top edge of the gusset and thebumper support member. Illustratively, the gusset attachment may beplanar.

In yet another illustrative embodiment, the rear impact guard may alsoinclude a first cross-brace coupled to the bumper support member and thegusset. Illustratively, the first cross-brace may extend diagonally atan angle across a forward-facing side of the bumper support member andthe gusset. Further illustratively, the first cross-brace may begenerally V-shaped in cross-section.

In still another illustrative embodiment, the rear impact guard may alsoinclude a second cross-brace coupled to the bumper support member andthe gusset. Illustratively, wherein the second cross-brace may extenddiagonally at an angle across a forward-facing side of the bumpersupport member and the gusset. Further illustratively, the second-crossmember may be parallel to and spaced-apart from the first cross-brace.The first and second cross-braces may each be generally V-shaped incross-section.

In another illustrative aspect, the rear impact guard may furthercomprise a floor assembly, a first support base associated with thefirst bumper support member, a second support base associated with thesecond bumper support member, and a third support base associated withthe third bumper support member. Each of the support bases may bepositioned between its respective bumper support member and the floorassembly.

In a further illustrative aspect, the rear impact guard may furthercomprise a fourth bumper support member and a fourth support baseassociated with the fourth bumper support member. The first and thirdbumper support members may be positioned to the left of a longitudinalaxis of the trailer. The second and fourth bumper support members may bepositioned to the right of a longitudinal axis of the trailer whenviewed from the rear.

In another illustrative embodiment of the rear impact guard, the floorassembly may include a pair of spaced apart slide rails extendinggenerally perpendicular to and forwardly away from the bumper, and aplurality of spaced apart cross members positioned over and generallyperpendicular to the pair of slide rails. Illustratively, the firstsupport base and the fourth support base each include a cover. The firstand fourth bumper support members and their associated first and fourthsupport bases may be positioned outboard of the slide rails. The secondsupport base may include a cutout. The cutout may be positioned belowthe slide rail in proximity to the first bumper support member. Thefirst and fourth support bases may further include a pair of uprightgussets or walls oriented generally transversely, with a gap betweenthem. A generally upright web member may extend through the gap betweenthe pair of upright walls or gussets, which illustratively are coupledwith the lower surface in a generally perpendicular relationship.Illustratively the walls and the web each have a generally trapezoidalshape. Web member illustratively extends from a front arm along a lowersurface and through the gap between the upright walls and continue alonga rear arm. The web member extends about half way up the rear arm.Illustratively, web member may be attached together, illustratively forexample by welding, with the front arm and the lower surface.

In yet another illustrative aspect of the rear impact guard, each of thesecond and third support bases may comprise a first continuous memberhaving a first lower surface including at one end a generally upstandingfirst front arm and at an opposing end a first rear arm extending at anangle generally upwardly and away from the first lower surface. Anupside down U-shaped cover may be positioned between the first front armand the first rear arm downwardly toward the first lower surface. Thefirst and fourth support bases illustratively may comprise a secondcontinuous member having a second lower surface including at one end agenerally upstanding second front arm and at an opposing end a secondrear arm extending at an angle generally upwardly and away from thesecond lower surface. The second rear arm may include the cutout.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a rear impact guard of the presentdisclosure showing the rear impact guard including two vertical supportmembers coupled to the underside of a rear door frame and floor assemblyof a trailer.

FIG. 1B is another view of the rear impact guard of FIG. 1A.

FIG. 2 is a perspective view of another rear impact guard of the presentdisclosure showing the rear impact guard including four vertical supportmembers.

FIG. 3 is a perspective view of a portion of the rear impact guard ofFIG. 2 showing the two inner bumper support members of the rear impactguard.

FIG. 4 is a side view of the rear impact guard of FIGS. 2-3.

FIG. 5 is a perspective view of a portion of one of the bumper supportmembers of the rear impact guard of FIGS. 2-4.

FIG. 6 is a top view of the portion of one of the bumper support membersshown in FIG. 5.

FIG. 7 is a rear view of the portion of one of the bumper supportmembers shown in FIGS. 5 and 6.

FIG. 8 is a perspective view of an alternative bumper support member ofan alternative rear impact guard (shown in FIG. 12) of the presentdisclosure.

FIG. 9 is another perspective view of the bumper support member of FIG.8.

FIG. 10 is a perspective view of a portion of the bumper support memberof FIGS. 8 and 9.

FIG. 11 is a perspective view of another portion of the bumper supportmember of FIGS. 8 and 9.

FIG. 12 is a perspective view of a rear impact guard including thebumper support member of FIGS. 8 and 9.

FIG. 13 is a perspective view of another alternative bumper supportmember similar to that shown in FIGS. 8 and 9.

FIG. 14 is a plan view of a first flat component to be formed into afirst portion of the bumper support member of FIG. 13.

FIG. 15 is a plan view of a second flat component to be formed into asecond portion of the bumper support member of FIG. 13.

FIG. 16 is a perspective view of an alternative rear impact guard of thepresent disclosure similar to the rear impact guard shown in FIG. 12 andalso including a gusset coupled to each of the bumper support members ofFIGS. 8 and 9.

FIG. 17 is a rear view of the rear impact guard of FIG. 16.

FIG. 18 is a rear perspective view one of the bumper support members ofthe rear impact guard of FIGS. 16 and 17 with the gusset attachedthereto.

FIG. 19 is a top view of the bumper support member and gusset of FIG.18.

FIG. 20 a front perspective view of the bumper support member and gussetof FIG. 18.

FIG. 21 is a perspective view of one of the gussets of the rear impactguard of FIGS. 17 and 18.

FIG. 22 is a plan view of a flat component to be formed into one of thegussets of the rear impact guard of FIGS. 17 and 18.

FIG. 23 is a top view of the gusset of FIG. 21.

FIG. 24 is a rear perspective view of an alternative bumper supportmember and gusset further including a gusset attachment coupled to a topportion of the gusset.

FIG. 25 is a front perspective view of the bumper support member,gusset, and gusset attachment of FIG. 24.

FIG. 26 is a front perspective view of the bumper support member and thegusset attachment of FIGS. 24 and 25 coupled to an alternative gusset.

FIG. 27 is a front perspective view of the bumper support member, thealternative gusset, and gusset attachment of FIG. 26, and furtherincluding a first and a second cross-brace each coupled at a first endto the gusset and at a second end to the bumper support member.

FIG. 28 is a front view of the bumper support member, the alternativegusset, the gusset attachment, and the first and second cross-braces ofFIG. 27.

FIG. 29 is a perspective view of the gusset attachment of FIGS. 24-28.

FIG. 30 is a front perspective view similar to FIG. 27 showing thebumper support member, the gusset of FIGS. 18-20, the gusset attachment,and the first and second cross-braces.

FIG. 31 is a plan view of a flat component to be formed into the firstcross-brace of FIGS. 27, 28, and 30.

FIG. 32 is a plan view of another flat component to be formed into thesecond cross-brace of FIGS. 27, 28 and 30.

FIG. 33 is a perspective view of the gusset attachment of FIGS. 24-29.

FIG. 34 is a perspective view of an alternative rear impact guard of thepresent disclosure showing the rear impact guard including four verticalsupport members coupled to the underside of a rear door frame and floorassembly of a trailer.

FIG. 35 is a perspective view of a portion of the rear impact guard ofFIG. 34 showing an outer bumper support member and an inner bumpersupport member of the rear impact guard.

FIG. 36 is a perspective view of a portion of the rear impact guard ofFIG. 34 showing an outer bumper support member including an outersupport base and an inner bumper support member including an innersupport base of the rear impact guard.

FIG. 37 is a plan view of a first flat component to be formed into afirst portion of the outer bumper support member of FIG. 34.

FIG. 38 is a plan view of a first flat component to be formed into afirst portion of the inner bumper support member of FIG. 34.

FIG. 39 is a perspective view of the outer support base of FIG. 36.

FIG. 40 is a perspective view of the inner support base of FIG. 36.

FIG. 41 is a front perspective view of a portion of the rear impactguard of FIG. 34 showing an outer bumper support member including theouter support base and an inner bumper support member including theinner support base of the rear impact guard coupled to the floorassembly.

FIG. 42 is another front perspective view of a portion of the rearimpact guard of FIG. 34 showing an outer bumper support member includingthe outer support base and an inner bumper support member including theinner support base of the rear impact guard coupled to the floorassembly.

FIG. 43 is a perspective view of an alternative rear impact guard of thepresent disclosure showing the rear impact guard including threevertical support members coupled to the underside of a rear door frameand floor assembly of a trailer.

FIG. 44 is another view of the rear impact guard of FIG. 43.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to illustrative embodiments shownin the attached drawings and specific language will be used to describethe same. While the concepts of this disclosure are described inrelation to a truck trailer, it will be understood that they are equallyapplicable to other vehicles generally, and more specifically toconventional flat-bed and/or box or van type trailers, examples of whichinclude, but should not be limited to, straight truck bodies, smallpersonal and/or commercial trailers and the like. Accordingly, thoseskilled in the art will appreciate that the present invention may beimplemented in a number of different applications and embodiments and isnot specifically limited in its application to the particularembodiments depicted herein.

A trailer 10 of the present disclosure includes a rear impact guard 12,also known as rear impact guard assembly 12, coupled to and dependingdownwardly from the bottom of the trailer rear frame 18, also known astrailer rear frame assembly 18, and rear end of a portion of the floorassembly 14 of the trailer 10. The rear impact guard 12 is formed as aseparate unit from a storage container (not shown) of the trailer 10 andcan be secured onto the storage container after assembly.Illustratively, the storage container includes sidewalls 16 (only one ofwhich is shown in FIG. 1A) and the floor assembly 14 coupled to andextending between the sidewalls 16. The storage container of the trailer10 further includes a rear end wall assembly 18 including an end wallframe 20 and a door (not shown) coupled to the frame 20. While a post 56may be coupled to the frame 20, illustratively it may replace the frame20 (FIGS. 34 and 43). Rear frame assembly 18 is coupled to both thesidewalls 16 and the floor assembly 14. The storage container of thetrailer 10 further includes a front end wall assembly (not shown)coupled to the sidewalls 16 and the floor assembly 14, as well as a roofassembly (not shown) coupled to the sidewalls 16 and the rear end wallassembly 18.

A pair of conventional slide rails 36 of the floor assembly 14 areattached beneath I-beam cross-members 38 (only one of which isillustratively shown in FIG. 1A) of the floor assembly, as shown inFIGS. 1A, 1B, 34, 43, 44. A conventional slidable rear undercarriageassembly (not shown) is mounted in a conventional manner to the sliderails 36. The ends of each cross-member 38 of the floor assembly 14 arecoupled to a base rail 40 of each respective sidewall 16. The baserail40 extends the length of the storage container and is preferably formedof aluminum which may be extruded.

As noted above, the floor assembly 14 includes a plurality ofspaced-apart cross-members 38 attached to the base rail 40 of eachsidewall 16. Each cross-member 38 is integrally formed from an I-beamthat includes an upper horizontal flange 42, a lower horizontal flange44, and a vertical web 46 extending between the upper and lower flanges42, 44 at the midpoint thereof. Each cross-member 38 extends across thewidth of the storage container. A floor 50, including a plurality offloor boards, generally sits on the upper surface of the cross-members38.

Slide rails 36 are connected to the underside of cross-members 38 atspaced-apart positions, and extend generally along the length of thestorage container. As is known in the art, the slide rails 36 areelongated members which include a plurality of spaced-apart apertures 52therethrough. This allows the undercarriage assembly (not shown) to besecured to the slide rails 36 at a variety of positions.

Illustratively, the rear end wall assembly 18 includes the rear frame 20which forms a rectangular opening into which the rear door or doors (notshown) are provided. The rear frame 20 includes an elongated horizontalsill 54, a pair of vertical posts 56 that extend upwardly from theopposite ends of the sill 54, and an elongated horizontal top member,i.e., rear door header, (not shown). The posts 56 are connected to therespective sidewalls 16 by rivets, but may be connected by any suitablefastener, weld, and/or adhesive. The opposite ends of the sill 54 areconnected to the respective base rails 40 by known welding, but may beconnected in any suitable manner. Illustratively, the sill 54 includes afantail 58 and a base plate 60 attached to the underside of the fantail58. As noted and seen in FIGS. 34, 43, and 44, the rear frame 20 maycomprise an extended post 56. Illustratively, sill 54 may include aplurality of spaced apart cut outs or apertures (FIGS. 34, 43, 44).

As noted above, the rear impact guard 12 is coupled to the rear end walland underside of the floor assembly 14 of the trailer 10. In particular,the rear impact guard 12 is coupled to the base plate 60 of the rearsill 54 and to the slide rails 36 of the trailer 10.

Illustratively, as shown in FIGS. 1A and 1B, the rear impact guard 12,also known as rear impact guard assembly 12, includes a horizontalbumper 130 as well as two vertical bumper support members 72. Further,illustratively, the rear impact guard 12 may include two additionalbumper support members 70, as shown in FIG. 2, for example. As shown inFIG. 2, the additional bumper support members 70 are provided outsidethe two inner vertical bumper support members 72. As such, the outervertical bumper support members 72 are positioned at a location outsidethe slide rails 36. Accordingly, the rear impact guard 12 shown in FIG.2 includes right and left pairs of spaced-apart vertical bumper supportmembers 70, 72 such that the illustrative rear impact guard 12 of FIG. 2includes four vertical bumper support members. Each pair of verticalbumper support member includes an outermost vertical bumper supportmember 70 and an innermost vertical bumper support member 72.Illustratively, the outermost vertical bumper support member 70 mayprovide offset impact protection to vehicles in a rear-impact accidentwith the trailer 10. FIG. 2 illustrates both pairs of vertical supportbumper members 70, 72; however, only the innermost two vertical bumpersupport members are shown in FIG. 3 and described herein. As such, itshould be understood that the outermost two vertical bumper supportmembers 70 are identical in shape and function to the innermost verticalbumpers. It should be understood that while the rear impact guard 12 mayinclude two vertical bumper support members, as shown in FIGS. 1A and1B, as well as four vertical bumper support members as shown in FIG. 3,that it is within the scope of this disclosure for the rear impact guardto include any suitable number of vertical bumper support memberspositioned at any suitable location along the length of the horizontalbumper 130.

Illustratively, the outermost vertical bumper support member 70 ispositioned farther outward from a longitudinal centerline of the trailer10 than the innermost vertical bumper support member 72. In other words,the outermost vertical bumper support member 70 is closer to the nearestsidewall 16 of the trailer 10 than the innermost vertical bumper supportmember 72. As is discussed in greater detail below, such positioning ofthe inner and outermost vertical bumper support members 70, 72 providesthat each may be coupled to different portions of the bottom of thefloor assembly 14 of the trailer 10.

Because the outermost and innermost vertical bumper support members 70,72 are identical in structure, only the innermost vertical bumpersupport member 72 is described in detail herein. Like reference numeralsare used to denote like components of the inner and outer verticalsupport members 70, 72. Illustratively, the vertical bumper supportmember 72 includes two mirror-image shells 74, various views of a singleone of which is shown in FIGS. 5, 6, and 7. Illustratively, each shell74 is welded to one other mirror-image shell 74 to form a singlevertical bumper support member 72. Thus, each shell 74 is a generallyhollow component including angles, or corners, distributed to theoutside of the bumper support members 70, 72 thus providing increasedtorsional stability of the bumper support members 70, 72 while alsominimizing the overall weight of the rear impact guard 12. Reducing theweight of the rear impact guard operates to reduce the overall weight ofthe trailer thus allowing the operator to either increase the loadcapacity of the trailer and/or lower the fuel consumption by thetractor-trailer combination.

Each shell 74 includes a rear, vertical plate 76, a side plate 78, aswell as various flange members (described below) coupled to the sideplate 78. As shown in FIG. 5, the vertical plate 76 is rectangular inshape and includes three apertures 80 therethrough. The top-mostaperture 80 is provided to receive a fastener 170 therethrough in orderto couple the vertical bumper support member 72 to a mounting bracket160 which is then coupled to the rear door sill 54 of the trailer 10, asis discussed in greater detail below. The two lower apertures 80 areprovided to receive therethrough a bolt or other fastener in order toattach a rubber bumper (not shown), for example, to protect the verticalbumper support members 70, 72 in the event the bumper support members70, 72 impact a loading dock or other structure, for example. As shownin FIGS. 4 and 5, the side plate 78 is generally trapezoidal in shapeand includes a vertical member 82 coupled to one vertical edge 84 of thevertical plate 76, an upper horizontal member 86 coupled to an upper endof the vertical member 82 and configured to extend forwardly (relativeto the trailer 10) in a direction perpendicular to the vertical member82, and a lower horizontal member 87 coupled to a lower end of thevertical member 82 and similarly configured to extend forwardly in adirection perpendicular to the vertical member 82. An angled member 88of the side plate 78 extends between and is coupled to the forward endsof the upper and lower horizontal members 86, 77. As shown in FIG. 4, aportion of the angled member 88 extends below a lowermost-edge of thevertical plate 76 and the vertical member 82. An aperture 90 of the sideplate 78 is generally trapezoidal in shape and defined by the verticalmember, 82, upper horizontal member 86, lower horizontal member 87, andangled member 88 of the side plate 78.

Illustratively, while the side plate 78 is described above as beinggenerally trapezoidal in shape, it should also be understood that theside plate 78 is also generally triangular in shape and that the smalllower horizontal member 87 be considered as part of the vertical member82 and/or the angled member 88. In other words, it is within the scopeof this disclosure to consider the side plate 78 to be generallytriangular in shape and including the vertical member 82, the upperhorizontal member 86 and the angled member 88.

The shell 74 further includes a pair of flanges 92 coupled to a top edge93 of the upper horizontal member 86. The flanges 92 are spaced-apartfrom each other and configured to extend inwardly in a directionperpendicular to a plane defined by the upper horizontal member 86.Illustratively, the flanges 92 define a horizontal plane that isgenerally parallel to a plane defined by the floor boards 50 of thefloor assembly 14. As shown in FIG. 5, one of the flanges 92 includes anaperture 92 a formed therethrough. As is discussed in greater detailbelow, the aperture 92 a is configured to receive a fastener, such as abolt, to couple the vertical bumper support member 72 to the floorassembly 14 of the trailer 10.

The shell 74 further includes another flange 94 coupled to an outer edge95 of the angled member 88 of the side plate 78. As shown in FIGS. 4 and6, the flange 94 extends inwardly in a direction generally perpendicularto the angled member 88 and includes a flange plate 98 and three flangemembers 96 extending away from the flange plate 98 such that the flange94 is generally shaped like the number three when the shell 74 is viewedfrom a rear end as shown in FIG. 7. Finally, the shell 74 includes yetanother flange 100 extending inwardly from a lower, vertical edge 102 ofthe angled member 88. The flange 100 is perpendicular to the planedefined by the side plate 78 and includes an aperture 104 formedtherethrough.

As noted above, the vertical bumper support member 72 includes twomirror-image shells 74. The shells 74 are welded to one another along anouter edge 110 of each respective vertical plate 76, upper flanges 92,flange portions 96 of the angled flange plate 94, and bottom flange 100to form a central weld seam 120 (shown in FIGS. 1-3) along the edgeportions of each of the vertical plate 76 and the side plate 78. Asshown in FIG. 3, the edges 110 of the vertical plates 76 of each shell74 are welded together, and the edges 110 of the flanges 92, 96, 100 ofthe side plate 76 of each shell 74 are welded to each other to form asingle vertical bumper support member 70 and 72. While the illustrativeshells 74 of each vertical support bumper 70, 72 disclosed herein arewelded to each other along the edges 110 of each shell 74, it is withinthe scope of this disclosure the shells 74 to be coupled to each otherby other suitable fasteners, such as through the use of bolts, rivets,screws, and/or adhesives, for example. Further, while the illustrativevertical bumper support members 70, 72 are made of two separate shells74 which are coupled together, it is within the scope of this disclosurefor each vertical bumper support member 70, 72 to be made of any numberof components such that each vertical bumper support member 70, 72 mayinclude one, unitary component, or a plurality of separate componentsthat are coupled to each other using any suitable fastener or fasteningmeans.

Illustratively, the assembled vertical bumper support member 72 includestwo apertures 90 formed through the side plate 78 of each shell 74 ofthe bumper 72 as well as two apertures 122 formed between the adjoiningflange plates 94 of the shells 74. A cut-out portion 124, half of whichis shown by the shell 74 in FIG. 5, of the vertical bumper supportmember 72 is configured to receive the horizontal bumper 130. Thehorizontal bumper 130 is generally formed as a tube having a front wall140, a rear wall 142, a top wall 144, and a bottom wall 146. Inparticular, the front wall 140 and the bottom wall 146 are formed of asingle piece of steel having one bend formed therein to form an L-shapedmember, and the top wall 144 and the rear wall 142 are similar formed ofa single piece of steel having one bend formed therein to form anL-shaped member. Each L-shaped member is welded to each other L-shapedmember to form the horizontal bumper 130. As is stated above in regardto the vertical bumper support members 70, 72, the horizontal bumper 130may comprise one component or any number of components coupled to eachother by any suitable means including, for example, through the use ofrivets, screws, bolts, welds, and/or adhesives.

As noted above, the horizontal bumper 130 is received within the cut-outportion 124 of the vertical bumper support members 70, 72 such that abottom edge 150 of the vertical plate 76 and a common bottom edge 151 ofthe lower horizontal member 87 and the vertical member 82 of the sideplate 78 of each shell 74 are engaged with and rest upon the top wall144 of the horizontal bumper 130. Further, a rearwardly-facing surface152 of the flange 100 of each shell 74 is engaged with the front wall140 of the horizontal bumper 130. Illustratively, the horizontal bumper130 is welded and bolted to each of the two pairs of vertical bumpersupport members 70, 72. In particular, a bolt 131 (shown in FIG. 4) isreceived through an aperture (not shown) of the front wall 140 of thehorizontal bumper 130 and the aperture 104 of the flange 100 of eachshell 74 in order to further fasten horizontal bumper 130 to thevertical bumper support members 70, 72. While the vertical bumpersupport members 70, 72 are coupled to the horizontal bumper 130 in themanner described above, it is within the scope of this disclosure tocouple the horizontal bumper 130 and the vertical bumper support members70, 72 using other suitable fasteners including additional or fewerbolts, welding additional or fewer welds, rivets, screws, and/oradhesives, for example.

As shown in FIGS. 1 and 2, the vertical bumper support members 70, 72are coupled to the rear door sill 54 by mounting brackets 160.Illustratively, each mounting bracket 160 is generally U-shaped andincludes a front arm 162, a rear arm 164, and a center member 166coupled to and extending between each of the front and rear arms 162,164. As shown in FIGS. 1 and 2, the rear arm 164 is coupled to the upperportion of the adjoining vertical plates 76 of each vertical bumpersupport member 70, 72. Specifically, the rear arm 164 is coupled to thevertical plates 76 by a fastener, such as a bolt 170 received throughthe upper-most aperture 80 of each vertical plate 76 as well as twocorresponding apertures (not shown) of the mounting bracket 160. Thecenter member 166 is adjacent to and coupled with the adjacent,rear-most flanges 92 of each vertical bumper support member 70, 72 by afastener, such as a bolt (not shown) received through the aperture 92 aof each flange 92 as well as through two corresponding apertures (notshown) of the center member 166 of the mounting bracket 160. The upperends of the front and rear arms 162, 164 of the mounting bracket 160 arewelded to the bottom surface of the base plate 60 of the sill 54.

As noted above, the rear impact guard 12 includes two pairs ofspaced-apart vertical bumper support members or brackets 70, 72 and ahorizontal bumper 130 which is mounted to the lower ends of the bumpersupport members or brackets 70, 72. The horizontal bumper 130 is formedas a closed end tube. The bumper 130 is secured to the lower ends ofbumper support members or brackets 70, 72 by suitable means, such aswelding. Illustratively, the spacing and placement of the verticalbumper support members 70, 72 or brackets 70, 72 with respect to eachother may be varied. In other words, the outer-most vertical bumpersupport members or brackets 70 may be moved inwardly or outwardlyrelative to the longitudinal axis of the trailer 10. Further, theinner-most vertical bumper support members 72 or brackets 72 may bemoved inwardly or outwardly relative to the longitudinal axis of thetrailer 10.

It should be understood that that while the particular rear impact guard12 shown in FIGS. 2-7 and described above includes two vertical bumpersupport members 70 and two vertical bumper support members 72, the rearimpact guard may be configured to only include two spaced-apart verticalsupport bumper support members 72, such as that shown in FIG. 1, forexample. Additionally, a rear impact guard 12 may be configured toinclude any number of vertical bumper support members 70 or 72.

Looking now to FIGS. 8-12, an alternative rear impact guard 212 isprovided. The rear impact guard 212 includes two spaced-apart verticalbumper support members 272, as shown in FIG. 12, and the horizontalbumper 130 coupled to each of the vertical bumper support member 272.Because the vertical bumper support members 272 are identical instructure, only one of the vertical bumper support members 272 isdescribed in detail herein. Like reference numerals are used to denotelike components of the two vertical support members 272. It should beunderstood that while the particular rear impact guard 212 includes twovertical bumper members 272, the rear impact guard may be configured toinclude any suitable number of vertical bumper support members 272. Forexample, the rear impact guard 212 may be configured to include twoadditional vertical bumper support members 272 located generally at theouter ends of the horizontal bumper 130 such that the rear impact guard212 includes a total of four vertical bumper support members 272. Asnoted above in regard to the rear impact guard 12, the vertical bumpersupport member or members 272 may be located at any suitable position orpositions along the length of the bumper 130.

Illustratively, the vertical bumper support member 272 includes twomirror-image shells 274 (shown in FIG. 10) and a center member 275coupled to the shells 274. Illustratively, each shell 274 is welded toone other mirror-image shell 274 and the center member 275 is positionedbetween and welded to the two shells 274 to form a single verticalbumper support member 70. Each shell 274 includes a rear, vertical plate276 and a side plate 278 coupled to the vertical plate 276. As shown inFIG. 10, the vertical plate 276 is rectangular in shape and includesthree apertures 280 therethrough. Similar to the apertures 80 describedabove with regard to the vertical bumper support member 72, the upperaperture 280 is provided to bolt the bumper support member 272 to thefloor assembly 14 of the trailer 10 while the two lower apertures 280are provided to receive therethrough a bolt or other fastener in orderto attach a rubber bumper (not shown), for example, to protect thebumper members 272, 272 in the event the bumper members 272, 272 impacta loading dock or other structure, for example. The side plate 278 isgenerally triangular in shape and includes a vertical member 282 coupledto one vertical edge 284 of the vertical plate 276, an upper horizontalmember 286 coupled to an upper end portion of the vertical member 282and configured to extend forwardly (relative to the trailer 10) in adirection generally perpendicular to the vertical member 282, and anangled member 288 of the side plate 278 extending between and coupled tothe forward ends of the upper horizontal member 286 and the verticalmember 282. A notch 279 is formed between the angled member 288 and thevertical member 282. As shown in FIG. 10, an aperture 290 of the sideplate 278 is generally triangular in shape and defined by the verticalmember 282, the upper horizontal member 286, and the angled member 288of the side plate 278.

Illustratively, an angle 292 (shown in FIGS. 8 and 10) between thevertical plate 276 and the vertical member 282 is approximately 87degrees. Thus, the side plate 278 is not perpendicular to the verticalplate 276, but rather angles slightly inwardly such that when the twoidentical shells 274 are coupled together, as shown in FIG. 8, adistance 289 between a forward-most end of the side plates 278 issmaller than a distance 291 between a rearward-most end of the sideplates 278. In particular, the distance 289 is approximately 4 incheswhile the distance 291 is approximately 6 inches. It should beunderstood that while the angle 292 is approximately 87 degrees, theshell 274 may define any suitable angle between the vertical plate 276and the vertical member 282 that is less than 90 degrees, equal to 90degrees, or greater than 90 degrees.

The vertical bumper support member 272 or bumper bracket 272 furtherincludes a center member 275, shown in FIGS. 8 and 11, coupled to eachshell 274. The center member 275 includes an upper, horizontal member302 and a lower member 304. An illustrative angle 306 between the uppermember 302 and the lower member 304 is approximately 48 degrees.However, it should be understood that any suitable angle may be used.The angle member 275 is illustratively a one-piece member; however, itis within the scope of this disclosure for the angle member 275 to bemade of more than one component.

The upper member 302 includes two apertures 308 configured to receive afastener therethrough in order to couple the vertical bumper supportmember 272 to the undercarriage of the floor assembly 14 of the trailer10. The apertures 308 are configured to each receive a fastener, such asa bolt (not shown) to couple the vertical bumper support member 272 tothe floor assembly 14. A mounting bracket (not shown) the same as orsimilar to the mounting bracket 160 described above in regard to therear impact guard 12 may be used to couple the vertical bumper supportmembers 272 to the undercarriage of the floor assembly 14 in the same orsimilar manner as that described above in regard to the vertical bumpersupport members 70 and 72. The lower member 304 includes an elongatedaperture 310. The aperture 310 operates to lessen the amount of materialused to manufacture the vertical bumper support member 272, thusminimizing the overall weight of the member 272. The aperture 310 mayalso operate as a drainage holes for the bumper support member 272 whenthe member 272 is painted and/or galvanized via a hot, as is discussedin. For example, when the bumper support member 272 is painted and/orgalvanized via a hot-dip galvanization process, the paint or molten zincbath into which the bumper support member 272 may be submerged isallowed to drain from between the shells 274 and center member 275 viathe aperture 310, as is described in greater detail below. The lowermember 304 includes a central body 303 and side flanges 312 coupled tothe central body 303 and oriented at approximately a 90 degree angle toan inner surface 314 of the lower member 304 and oriented in a forwarddirection. The side flanges 312 operate to provide additional strengthto the lower member 304 to help prevent the lower member 304 frombuckling under compression.

As shown in FIG. 8, the center member 275 is generally located betweenthe two shells 274 of the vertical bumper support member 272 such thatan outer edge 320 of the angled member 288 of the shell 274 is weldedthe inner surface 314 of the lower member 304 of the center member 275.Further an upper edge 322 of the side member 278 of the shell 274 isalso welded to the upper member 302 of the angle member 275 such thatthe forward-most portion of the edge 322 is welded to a bottom surface324 of the upper member 302 while the rearward-most portion of the edge322 (adjacent the vertical member 276 of the shell 274) is welded to anouter edge 326 of the upper member 302. As shown in FIG. 8, theforward-most portion of the side member 278 is located inward of theouter edges 326 of the upper member 302 due to the angle 292 between thevertical member 276 and the side member 278 being less than 90 degrees.Illustratively, as noted above, the distance 289 between theforward-most ends of the horizontal member 286 of the shells 274 of eachvertical bumper bracket 272 or bumper support member 272 isapproximately 4 inches while a distance 293 between the outer edges 326of the upper member 302 is approximately equal to the distance 291, or 6inches. The shells 274 are also welded to each other along a verticaledge 330 of the vertical member 276 of each shell 274 in order to createa center weld seam 320 between the edges 330 of the vertical plate 276of each shell 274. It should be noted that while the center member 275is welded to the shells 274 of the vertical bumper support member 272 orbumper bracket 272 and the shells 274 of each vertical bumper supportmember 272 or bumper bracket 272 are welded to each other, thesecomponents may be coupled to each other by other suitable meansincluding through the use of adhesives as well as various mechanicalfasteners such as rivets, bolts, screws, etc. Further, as is discussedin greater detail below, while the illustrative vertical bumper supportmembers 272 are made of two separate shells 274 and a center member 275which are coupled together, it is within the scope of this disclosurefor each vertical bumper support member 272 to be made of any number ofcomponents such that each vertical bumper support member 272 may includeone unitary component, or a plurality of separate component that arecoupled to each other using any suitable fastener or fastening means.

Illustratively, as shown in FIG. 12, the vertical bumper support members272 are coupled to the top and front members 144, 140 of the horizontalbumper 130 similar to the manner in which the vertical bumper supportmembers 70, 72 are coupled to the horizontal bumper 130. In particular,a bottom edge 250 of the vertical plate 282 and a bottom edge 251 of thevertical member 282 of the side plate 278 of each shell 274 are engagedwith and rest upon the top wall 144 of the horizontal bumper 130.Illustratively, the horizontal bumper 130 is welded to each bumpersupport member 272 along the bottom edges 250, 251 of the shells 274 ofeach member 272. A bottom edge 253 of the center member 275 is welded tothe front wall 140 of the horizontal bumper 130. While the verticalbumper support members 272 are each coupled to the horizontal bumper 130in the manner described above, it is within the scope of this disclosureto couple the horizontal bumper 130 and the vertical bumper supportmembers 272 to each other using other suitable fasteners including theuse of bolts, additional or few welds, rivets screws, and/or adhesives,for example.

Looking now to FIG. 13, an alternative vertical bumper support member372 is provided. Illustratively, the vertical bumper support member 372is similar to the vertical bumper support members 272 described above.Thus, like references numerals are used to denote like components.Further, the vertical bumper support member 372 is coupled to both thefloor assembly 14 of the trailer as well as to the horizontal bumper 130in the same or similar manner as that described above in regard to thevertical bumper support members 272.

Different from the vertical bumper support member 272, each shell 274 ofthe illustrative vertical bumper support member 372 includes two uppercut-outs 371 formed along the upper edge 322 of the side plate 278.Further, each shell 274 of the bumper support member 372 of FIG. 13includes two notches 374 along the outer edge 320 of the angled member288 of the side plate 278. Illustratively, the notches 371, 374 operateto provide drainage holes of the bumper support member 372. For example,when the bumper support member 372 is painted and/or galvanized via ahot-dip galvanization process, the paint or molten zinc bath into whichthe bumper support member 372 may be submerged is allowed to drain frombetween the shells 274 and center member 275 via the notches 371, 374once the bumper support member 372 is removed from the bath. The notch279 provides further access for drainage of any liquid material intowhich the bumper support member 372 may be submerged. The upper-mostapertures 280 of the vertical plate 276 of each shell 274 may be used toreceive a hanger or hook (not shown) after the bumper support member 372is painted and/or galvanized in order to allow the excess paint and/orliquid zinc to drain from the bumper support member 372.

Illustratively, the notches 371 and 374 may also operate as a visualindicator during the welding process. In particular, the notches 374provide an indicator to the welder as to where to start and stop weldingwhen welding the outer edge 320 of each shell 274 to the center member275. Similarly, the notches 371 provide a visual indicator to the welderas to where to start and stop welding when welding the upper edge 322 ofeach shell 274 to the center member 275.

Illustratively, the bumper support members 272, 372 are each made of twoshells 274 and the center member 275 positioned between and coupled toeach of the two shells 274. Thus, the bumper support members 272, 372each include three main components. Further, the bumper support members70, 72 are each made of two shells 74 thus including two maincomponents. However, as noted above, the bumper support members 70, 72,272, 372 disclosed herein may be made of any number of suitablecomponents that are bent and/or configured into the shapes shown anddescribed above. For example, as shown in FIGS. 14 and 15, a generallyplanar first component 400 and a generally planar second component 402are provided. The first component 400 includes many of the same orsimilar features of the shells 274 described above such that the firstcomponent 400 may be bent or folded along the two fold lines shown inFIG. 14 in order to form a one-piece structure that is equivalent to twoshells 274 coupled to each other. In other words, the two shells 274 ofthe bumper support member 272 may be formed from the single component400. A single vertical plate 476 between the fold lines 410 of the firstcomponent 400 is generally the same size and shape as the portion of thebumper support member 272 formed by coupling the vertical plate 276 ofeach shell 274 together. Forming the two shells 274 of the singlecomponent 400 may provide a stronger vertical bumper support memberbecause the weld seam 220, 320 is eliminated.

The second planar component 402, shown in FIG. 15, may be bent along thefold line 412 in order to form the center member 275 of the bumpersupport members 272, 372. Bending the second planar component 402 alongthe fold lines 414 operates to differentiate the central body 303 andthe flanges 312 of the lower member 304. Illustratively, the planarcomponents 400, 402 may be bent along the respective fold lines 410, 412by a progressive die machine or a stamping press, for example. As notedabove, it should be understood that while the vertical bumper supportmembers 272, 372 may be configured from the two planar components 400,402 shown in FIGS. 14 and 15, the vertical bumper support members 272,372 may also be formed from a single planar component (not shown) thatis able to be bent and configured to form the vertical bumper supportmembers 272, 372. Similarly, the vertical bumper support members 70, 72may be formed from a single planar component (not shown) that is able tobe bent and configured to form the vertical bumper support members 70,72 or bumper support brackets 70, 72.

Illustratively, the vertical bumper support members 70, 72, 272, 372,970, 974 or brackets 70, 72, 272, 372, 970, 974 disclosed herein aremade from advanced high strength steel such as, but not limited to,DOMEX® hot-rolled steel from SSAB Tunnplat in Sweden. In particular,thin steel sheets (i.e., approximately 3 millimeters) of advanced highstrength steel are used to fabricate the above described components ofthe vertical bumper support members or brackets 70, 72, 272, 372, 970,974. Further, the horizontal bumper 130 may also be made of the sameadvanced high strength steel. However, it should be understood that eachcomponent of the rear impact guards described herein may be made fromany suitable material including high strength steel, metals, metalalloys, plastics, and/or composites.

Illustratively, various bumper support members 70, 72, 272, 372, 970,974 are shown and described herein. As noted herein, each of thesebumper support members 70, 72, 272, 372, 970, 974 includes variouscomponents which cooperate to define a hollow, generally triangularprism. The hollow prism shape of each bumper support member 70, 72, 272,372, 970, 974 operates to increase bending and torsional strength of thebumper support member while also minimizing the amount of material usedto manufacture each member, thus minimizing weight and material cost ofeach member. The hollow prism includes first and second generallytriangle-shaped faces that are spaced-apart from each other as well asfirst, second, and third sides that are each positioned between andcoupled to the first and second triangle-shaped faces. Illustratively,the side plates 78, 278 of the bumper support members 70, 72, 272, 372define the first and second spaced-apart generally triangle-shapedfaces. The two adjacent vertical plates 76, 276 that are welded togetheras well as the single vertical plate 476 of the component 400 shown inFIG. 14 define the first side of the prism. The flanges 92 of two shells74 that are welded together define the second side of the prism whilethe horizontal member 302 of the center member 275 of the bumper supportmembers 272, 372 define the second side of the prism. The flanges 96 oftwo shells of the bumper support members 70, 72 that are welded togetherdefine the third side of the prism while the lower member 304 of thecenter member 275 of the bumper support members 272, 372 also define thethird side of the prism. The prism is illustratively a right-triangleprism such that the first side and the second side are generallyperpendicular to each other.

Looking now to FIGS. 16-20, an alternative rear impact guard 512 isprovided. As with the other rear impact guard embodiments disclosedherein, the rear impact guard 512 is configured to be coupled to anddepend downwardly from the bottom of the rear frame, such as rear frame18, and the rear end of a portion of the floor assembly, such as floorassembly 14, of a trailer the same as or similar to the portion oftrailer 10 shown in FIG. 1A. The rear impact guard 512 includes a rightand left vertical bumper support member 372 that are each the same as orsimilar to the vertical bumper support member shown in FIG. 13 and madefrom the first planar component 400 shown in FIG. 14 and the secondplanar component 402 shown in FIG. 15. As such, like reference numeralsare used to denote like components. The rear impact guard 512 furtherincludes a gusset 516 coupled to each of the right and left verticalbumper support members 372. Each gusset 516 is coupled to an outsideportion of the lower member 304 of the center member 275 of therespective vertical bumper support member 372. Illustratively, as shownin FIGS. 21-23, each gusset 516 generally defines a Z-shape when viewedfrom above, as shown in FIG. 23, and includes a triangular wall 518, amiddle wall 520 coupled to the triangular wall 518. Illustratively, thetriangular wall 518 defines a right-sided triangle. The triangular wall518 may be solid, as shown in FIGS. 21, 22, 24, and 25, for example, ormay include an aperture 570, as shown in FIGS. 16-20, in order to reducethe overall weight of the gusset 516.

The middle wall 520 is coupled to and extends along a hypotenuse edge523 of the triangular wall 518 and defines a shape similar to aparallelogram whereby the long sides of the middle wall 520 are parallelto each other but the short sides of middle wall 520 are not. Inparticular, the bottom, short side 521 of the middle wall 520 extendsfurther downwardly below a bottom side of the triangular wall 518. Eachgusset 516 further includes an end wall 522 coupled to the middle wall520 and extending along one side of the middle wall 520. The end wall522 defines a parallelogram. Illustratively, as shown in FIG. 23, afirst angle 530 between the triangular wall 518 and the middle wall 520is approximately 90 degrees while a second angle 532 between the middlewall 520 and the end wall 522 is similarly approximately 90 degrees. Thegusset 516 further includes notches 534 at the top and bottom of thegusset 516 between the triangular wall 518 and the middle wall 520.

The gusset 516 is illustratively formed from a planar component 550shown in FIG. 22. The planar component 550 is bent or folded along thetwo, parallel fold lines 552 shown in FIG. 22 in order to form theone-piece gusset 516. Illustratively, the planar component 550 may bebent along the fold lines 552 by a progressive die machine or a stampingpress, for example. As shown in FIG. 23 and described above, the planarcomponent 550 is bent along the parallel fold lines 552 to define the 90degree angles 530, 532 between the triangular wall 518, middle wall 520,and end wall 522 of the gusset 516. Illustratively, as described above,the gusset 516 is a one-piece, or unitary, component. However, thegusset 516 may be formed to include any number of separate componentsthat are coupled together to form or define the gusset 516.

As shown in FIG. 16-20, each gusset 516 of the rear impact guard 512 iscoupled to one of the vertical bumper support members 372. Specifically,an outer, vertical edge 560 of the gusset 516 is welded to an outerflange 562 of the center member 275. Illustratively, the outer flanges562 of the central member 276 are similar to the side flanges 312 of thecentral member 275 shown in FIG. 11; however, the outer flanges 562 areplanar with the central body 303 of the lower member 304 of the centermember 275 and are not bent 90 degrees as the side flanges 312 shown inFIG. 11. As such the outer-most outer flange 562 of each vertical bumpersupport member 372 is coupled to the vertical edge 560 of the gusset516. As shown best in FIG. 20, a bottom edge 563 of the triangular wall518 of the gusset 516 is generally aligned with a bottom edge 253 of thecenter member 275 and is also welded to the front wall 140 of thehorizontal bumper 130. The middle wall 520 and end wall 522 of thegusset 516 extend downwardly over the front face 140 of the horizontalbumper 130, as shown in FIG. 20 and are also welded to the front face140 of the bumper 130. As shown in FIG. 20, the bottom edge 582 of theend wall 522 is positioned approximately mid-way along a height of thefront face 140 of the bumper 130. In other words, the bottom edge 582 ofthe gusset 516 is positioned upwardly of the edge between the front face140 and the bottom face 146 of the horizontal bumper 130 to form astandard leg 527 of the gusset 516.

Alternatively, as shown in FIG. 26, the gusset 516 includes analternative middle wall 620 and an alternative end wall 622 such that abottom edge 682 of the outer wall 622 is positioned at the bottom edgeof the front face 140 of the horizontal bumper 130. Accordingly, abottom edge 621 of the middle wall 620 is longer than the bottom edge521 of the gusset 516 shown in FIG. 20, for example, in order to definean extended leg 627 of the gusset 516. It should be understood that thegusset 516 may be formed and configured such that the bottom edge of theend wall 522 of the gusset 516 is positioned at any height along thefront wall 140 of the horizontal bumper 130. Illustratively, the flange562 of the vertical bumper support member and the edge 560 of the gusset516 are welded to each other, while the other components of the gusset516 are welded to the horizontal bumper 130; however, it is within thescope of this disclosure to couple the gusset 516 and vertical bumpersupport member 372 to each other and to couple the gusset 516 to thebumper 130 using other suitable fasteners such as bolts, rivets, and/oradhesive in lieu of or in addition to one or more welds, for example.

Looking now to FIGS. 24, 25, and 33, a gusset attachment 600 is coupledto the gusset 516 of the rear impact guard 512. In particular, thegusset attachment 600 is coupled to a top edge 580 of the gusset 516 andengages and is coupled to a portion of the center member 275 of thevertical bumper support member 372. A bottom surface 602 of the gussetattachment 600 is welded to the top edge 580 of the gusset 516 in orderto generally close the open, Z-shape of the top edge 580 of the gusset516. Further, an inboard tip of the gusset attachment 600 rests againstthe planar surface of the central body 303 of the lower, angled member304 of the vertical bumper support member 372.

The gusset attachment 600 operates to further strengthen the gusset 516and vertical bumper support member 372 in the event of an impact by avehicle, for example. Particularly, the gusset attachment 600 mayprovide additional torsional strength to the rear impact guard 512. Asshown in FIG. 33, the gusset attachment 600 is a planar componentdefining five sides. Two pairs of opposite sides of the gussetattachment 600 are parallel to each other. In particular, sides 604 and606 are parallel to each other while sides 608 and 610 are parallel toeach other. Side 612 is not parallel to any other side of the gussetattachment 600. Illustratively, the gusset attachment 600 may alsodefine only four sides, as shown in FIGS. 27-29, for example.Illustratively, the rear impact guard 512 may include the gussetattachment 600, or may be provided without the gusset attachment 600.

Looking now to FIGS. 27-29, a first and second cross-brace 700, 702 ofthe rear impact guard 512 is used with the vertical bumper supportmember 372, the gusset 516 (including the standard leg 527 shown in FIG.30 and the extended leg 627 shown in FIG. 27), the and the gussetattachment 600. The first and second cross-braces 700, 702 are eachcoupled at a respective first end 701, 703 to the vertical bumpersupport member 372 and at a respective second end 705, 707 to the gusset516. In particular, the first end 701, 703 of each of the first andsecond cross-braces 700, 702 is coupled to the lower member 303 of thecenter member 275 of the vertical bumper support member 372, and thesecond end 705, 707 of each of the first and second cross-braces 700,702 is coupled to the illustrative middle wall 620 of the gusset 516.The first and second cross-braces 700, 702 are welded to each of thegusset 516 and the vertical bumper support member 372, but may becoupled to the gusset 516 and the vertical bumper support member 372using other suitable fasteners including, but not limited to, rivets,screws, and/or adhesive, for example. The cross-braces 700, 702 operateto further strengthen the rear impact guard 512 against impact forcesfrom another vehicle.

As shown in FIG. 31, the first cross-brace 700 is illustratively formedfrom a planar component 750. The planar component 750 is bent, orfolded, along the parallel fold lines 752 to form the generally V-shapedfirst cross-brace 700. The planar component 750 and cross-brace 700include notches 754 for drainage of any fluids that may accumulate on oraround the component. As shown in FIG. 32, the second cross-brace 702 isformed from a planar component 850. The planar component 850 is bent, orfolded, along the parallel fold lines 852 to form the generally V-shapedsecond cross-brace 702. The planar component 850 and cross-brace 702also include notches 854 for drainage of any fluids. Illustratively, theplanar components 750, 850 may be bent along the respective fold lines752, 852 by a progressive die machine or a stamping press, for example.Illustratively, the cross-braces 700, 702 are each a one-piece, orunitary, components. However, the cross-braces 700, 702 may be formed toinclude any number of separate components that are coupled together toform or define the cross-braces 700, 702.

Illustratively, the rear impact guard 514 illustratively includes thevertical bumper support member 372 and the gusset 514 (having both thestandard and extended legs 527, 627). The rear impact guard 514 may alsoinclude the gusset attachment 600, the first cross-brace 700, and/or thesecond cross-brace 702. In other words, the gusset attachment 600 andcross-braces 700,702 may be used alone or in combination with each otherand with the gusset 514 and vertical bumper support member 372. Further,it should be understood that the gusset 514, gusset support 600, andfirst and second cross-braces 700, 702 shown and discussed in FIGS.16-33 may each be used, alone or in combination, with any of thevertical bumper support members shown and disclosed herein.

Referring now to FIGS. 34-44, further illustrative rear impact guards912, 1212 are depicted. Illustratively, each embodiment of truck 10disclosed herein generally comprises one of the embodiments of rearimpact guard 12, 212, 512, 912, 1212 also known as a rear impact guardassembly 12, 212, 512, 912, 1212, a floor assembly 14, and a trailerrear frame or end wall assembly 18, wherein like reference numerals areused to denote like components herein throughout. The rear impact guardassembly, the floor assembly and the rear frame assembly 18 are coupledtogether illustratively as described herein.

As further described herein, the floor assembly 14 generally comprises anumber of generally parallel cross members 38 and a number of generallyparallel slide rails 36, with the cross members 38 and slide rails 36being generally perpendicular to one another as illustrated for examplein FIGS. 1A, 1B, 34 and 41-44. Illustratively, the rails 36 and crossmembers 38 may be connected through any suitable means including usingfasteners, or they may be welded together. The floor assembly 14illustratively may further include an intercostal 47 extending betweenand generally perpendicular to adjacent cross members 38 to supportcross members 38 as seen for example in FIGS. 34 and 43. Eachintercostal 47 may be positioned between the upper horizontal flange 42and lower horizontal flange 44 of each respective cross member 38. Thecross members 38 may include end wall 48 to seal off one or both ends ofthe cross member 38.

Illustratively, an end clip 967 may be coupled together with and extendgenerally perpendicularly between one or both ends of two or more crossmembers 38. End clips 967 may be included at both ends of the two ormore adjacent cross members 38 (FIGS. 34 and 43) and may be positionedover end wall(s) 48. End clips 967 provide more stiffness for the floorassembly 14 to support the load input from the bumper support members970, 974, etc. during an impact. The inner portion of the cross members38 are similarly supported by the intercostals 47. In the illustrativeembodiment, end clips 967 are welded to end walls 48.

For example, as illustrated in FIGS. 34 and 41-43, three cross members38 are connected or coupled together with a pair of spaced apart endclips 967. Outer support bases 960 and inner support bases 961 underliein perpendicular relationship those three cross members. In addition anintercostal 47 extends between two of the cross members 38 and anotherintercostal 47 extends between two of the cross members 38.

As seen for example in FIGS. 34 and 41-44, outer support bases 960 andinner support bases 961 may be positioned such that the each supportbase 960, 961 extends or underlies on or more of the cross members 38.As seen in FIGS. 34, 36, 41 and 42 a pair of spaced apart outer supportbases 960 and a pair of spaced apart inner support bases 961 may beused. Support bases 960 and support bases 961 are spaced apart from eachother. In FIGS. 43 and 44, a plurality of spaced apart support bases 960illustratively are used.

As seen in FIG. 39, support base 960 generally comprises a continuousmember having at one end a generally upstanding front arm 964. The frontarm 964 and lower surface 966 are generally perpendicular to oneanother. Rear arm 962 extends at an angle generally upwardly and awayfrom lower surface 966. Illustratively, front arm 964 includes aplurality of apertures. Rear arm 962 illustratively includes aperture940. Lower surface 966 illustratively includes aperture 942. A generallyupside down U-shaped cover 969 is positioned between front arm 964 andrear arm 962, with the U-shaped opening of cover 969 facing downwardlytoward lower surface 966. Cover 969 illustratively includes aperture977. Cover 969 further includes notch 975.

As best seen in FIG. 40, support base 961 generally comprises acontinuous member having at one end a generally upstanding front arm965. The front arm 965 and lower surface 966 are generally perpendicularto one another. A rear arm 963 extends at an angle generally upwardlyand away from lower surface 966. Illustratively, front arm 965 includesa plurality of apertures. Rear arm 963 illustratively includes ordefines a cutout 968. Cutout 968 is formed to receive a portion of sliderail 36 as shown in FIGS. 41 and 42. Upright gusset 971 or wall 971 andupright gusset 972 or wall 972 are coupled with lower surface 966 in agenerally perpendicular relationship. Illustratively, walls 971, 972have a generally trapezoidal shape. While not shown in FIG. 40, supportbase also includes web member 973 as seen in FIG. 41. Illustratively,web member 973 makes a connection with slide rail 36 along the loweredge of the vertical wall of the component. Web member 973 has agenerally trapezoidal shape. It is sandwiched in an upright orientationbetween walls 971, 972. Web member 973 illustratively extends from frontarm along lower surface 966, through the gap between upright wall 971and upright wall 972 and up along rear arm 963. Illustratively, webmember 973 has a lower edge that may be attached together,illustratively for example by welding, with lower surface 966.Illustratively, web member 973 has a right upstanding edge that may beattached together, illustratively for example by welding, with frontface 965. Upper edge of web member 973 extends from the front face 965,through the gap between walls 971, 972 and intersects rear arm 963partially up rear arm 963.

Support bases 960, 961 are coupled to trailer rear frame 18 as shown inFIGS. 41 and 42. Illustratively, support bases 960, 961 are coupled tofantail 48. Upstanding front arms 964, 965 of support bases 960, 961 arecoupled with trailer rear frame 18. Illustratively, support bases 960,961 extend away from and are cantilevered from trailer rear frame 18. Insome embodiments, support bases 960, 961 are bolted or otherwisefastened with trailer rear frame 18. In other embodiments, support bases960, 961 are welded with trailer rear frame 18. In some embodiments,support bases 960, 961 are bolted, welded, or otherwise fastened withcross members 38 and or bumper support members 70, 74, 270, 970, 974,etc.

Rear assembly 18, also known as the rear frame 18 or end wall 18, as hasbeen described, may include rear frame 20 or end wall frame 20. Rearassembly 18 may further include elongated horizontal sill 54. Verticalposts 56 may extend upwardly from the opposite ends of sill 54. Asnoted, in some embodiments, extended posts 56 may replace rear frame 20.Rear assembly 18 may further include an elongated horizontal top member,i.e., rear door header, (not shown). Posts 56 illustratively areconnected to respective sidewalls 16 by rivets, but may be connected byany suitable fastener, weld, and/or adhesive. The opposite ends of sill54 are connected to respective base rails 40 by known welding, but maybe connected in any suitable manner. Illustratively, sill 54 includes afantail 58 and a base plate 60 attached to the underside of the fantail58.

Illustratively, as shown in FIGS. 34-42, rear impact guard assembly 912,includes horizontal bumper 130 as well as two vertical bumper supportmembers 970 and two vertical bumper support members 974. Each outervertical bumper support member 970 illustratively is positioned at alocation outside the slide rails 36. Each inner vertical bumper supportmember 974 is positioned inboard of each outer bumper support member970. Further illustratively, each inner bumper support member 974 ispositioned generally under and inboard of respective slide rails 36.Accordingly, the rear impact guard 912 shown in FIG. 34 includes rightand left pairs of spaced-apart vertical bumper support members 970, 974such that the illustrative rear impact guard 912 of FIG. 34 includesfour vertical bumper support members 970, 974.

Each pair of vertical bumper support member includes an outermostvertical bumper support member 970 and an innermost vertical bumpersupport member 974. Illustratively, the outermost vertical bumpersupport member 970 may provide offset impact protection to vehicles in arear-impact accident with the trailer 10. FIG. 34 illustrates both pairsof vertical support bumper members 970, 974; however, only one pair ofvertical bumper support members 970, 974 are shown in FIGS. 35-36 and41-42 and described herein. As such, it should be understood that theother pair of vertical bumper support members 970, 974 are identical instructure and function to the described vertical bumpers 970, 974.

It should be understood that while the rear impact guard 912 may includetwo pairs of vertical bumper support members 970, 974, as shown in FIG.34, it is within the scope of this disclosure for the rear impact guard912 to include any suitable number of vertical bumper support members970 or 974 or pairs of bumper support members 970 and 974 positioned atany suitable location along the length of the horizontal bumper 130. Forexample, as will be further described, rear impact guard assembly 1212(FIGS. 43-44) illustratively includes a plurality of vertical bumpersupport members 970. For example, FIGS. 43-44 illustratively disclosethree spaced apart bumper support members 970, which are eachillustratively spaced apart from slide rails 36.

Illustratively, each outermost vertical bumper support member 970 ispositioned farther outward from a longitudinal centerline of the trailer10 than each innermost vertical bumper support member 974. In otherwords, outermost vertical bumper support member(s) 970 is closer to thenearest sidewall 16 of the trailer 10 than innermost vertical bumpersupport member(s) 974. Such positioning of the inner and outermostvertical bumper support members 970, 974 provides that each may becoupled to different portions of the bottom of the floor assembly 14 ofthe trailer 10.

Illustratively, vertical bumper support members 970, 974 comprise agenerally hollow component including angles, or corners, distributed tothe outside of the bumper support members 970, 974 thus providingincreased torsional stability of the bumper support members 970, 974while also minimizing the overall weight of the rear impact guard 912.Reducing the weight of the rear impact guard operates to reduce theoverall weight of the trailer thus allowing the operator to eitherincrease the load capacity of the trailer and/or lower the fuelconsumption by the tractor-trailer combination.

Illustratively, bumper support member 970, 974 is generally triangularin shape. As noted above for bumper support members 70, 72, 272, 372,bumper support member 970, 974 may be made of any number of suitablecomponents that are bent and/or configured into the shapes shown anddescribed above. Bumper support member 970 includes vertical member 476or vertical plate 476 sandwiched between and generally perpendicular tospaced apart angle members 288. A center member 275 or angle member 275may be positioned between or over the spaced apart angle members 288.

Bumper support member 970 may be formed from planar component 1000,which is illustratively trapezoidal in shape (FIG. 37). Planar member1000 includes vertical member 476 with angled member 288 extending oneither side of vertical member 976. Planar member 1000 may be bent orfolded along the two fold lines 1010 shown in FIG. 37 in order to form aone-piece structure. Single vertical plate or member 476 located betweenthe fold lines 1010 is generally the same size and shape as the portionof the bumper support member 272 formed by coupling the vertical plate276 of each shell 274 together.

While the angle members 288 could be welded or otherwise connected tovertical member 976, forming the shell of bumper support member 970, 974from single planar component 1000 may provide a stronger vertical bumpersupport member. Planer component 1000 further includes apertures 378.Each aperture 378 is formed on each side of member 476. Planer component1000 further includes notches 376 formed along a lower portion of angledmember 288.

Bumper support member 974 may be formed from planar component 1100,which is illustratively trapezoidal in shape (FIG. 38). Planar member1100 includes vertical member 476 with angled member 988 extending oneither side of vertical member 476. Planar member 1100 may be bent orfolded along the two fold lines 1110 shown in FIG. 38 in order to form aone-piece structure. Single vertical plate or member 476 located betweenthe fold lines 1110 is generally the same size and shape as the portionof the bumper support member 272 formed by coupling the vertical plate276 of each shell 274 together. The planer component 1100 includes anupper horizontal member 986 and an angled member 988. The horizontalmember 986 is relatively shorter than horizontal member 286 to cause anangle of the angled member 988 to be smaller than the angle of theangled member 288.

While the angle members 988 could be welded or otherwise connected tovertical member 476, forming the shell of bumper support member 974 fromsingle planar component 1100 may provide a stronger vertical bumpersupport member. Planer component 1100 further includes apertures 378.Each aperture 378 is formed on each side of member 476. Illustratively,the apertures 378 of bumper support member 974 align with apertures ofbumper support members 970. Planer component 1100 further includesapertures 990. Planar components 1000, 1100 may be folded or bent asdescribed by a progressive die machine or a stamping press, for example.As noted above, it should be understood that while the vertical bumpersupport members 970, 974 may be configured from planar components 1000,1100 and center member 275, the vertical bumper support members 970, 974may also be formed from a single planar component (not shown) that isable to be bent and configured to form the vertical bumper supportmembers 970, 974.

A rear impact guard 1212 is shown in FIGS. 43 and 44. Rear impact guard1212 includes three bumper support members 970 and three support bases960. The three bumper support members 970 are spaced apart aboutequidistant from one another. One of the bumper support members 970 islocated about midway along horizontal bumper 130. Rear impact guard 1212further includes center member 277. Center member 277 is substantiallysimilar to center member 275. However, an upper member 305 of centermember 277 is relatively shorter than upper member 302 of center member275.

In the illustrative embodiment, bumper support members 70, 74, 270, 272,372, 970, 974, etc. and horizontal bumper 30 comprise high strengthsteel. Illustratively, The floor assembly 14 and the support bases 960,961 comprise 50K or 80K steel. In other embodiments, any number ofcomponents may comprise high strength steel or any other suitablematerial.

The floor assembly 14 is bolted or fastened to the rear frame 18 in theillustrative embodiment. Illustratively, rear impact guard 912, 1212 arebolted or fastened to the rear frame 18. The rear impact guard 912, 1212and the floor assembly are not directly connected, in the illustrativeembodiment, but the support bases 960, 961 transmit loads when the rearimpact guard 912, 1212, etc. apply a force to the support bases 960,961, for example, during an impact event. In some embodiments, thebumper support members 70, 72, 970, 974, etc. are spaced apart so that acar cannot collide with the rear impact guard 12, 912, 1212, etc.without colliding with at least one bumper support member 70, 72, 970,974, etc. In some embodiments, the bumper support members 70, 72, 970,974, etc. are positioned about three inches inward from the widestportion of the trailer 10.

Vertical bumper support member 970, as shown in FIGS. 34-36 and 42-44,may be welded, bolted, or otherwise fastened with bumper 130 and rearframe 18. The rear frame assembly 18 includes the rear frame 20 whichforms a rectangular opening into which the rear door or doors (notshown) are provided. As noted above, the rear impact guard 12, 912,1212, etc. may be coupled to the rear end wall and underside of thefloor assembly 14 of the trailer 10. In particular, the rear impactguard 12, 912, 1212 may be coupled to the base plate 60 of the rear sill54 and to the slide rails 36 of the trailer 10.

While the invention has been illustrated and described in detail in theforegoing drawings and description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly illustrative embodiments thereof have been shown and described andthat all changes and modifications that come within the spirit of theinvention are desired to be protected.

What is claimed is:
 1. A rear impact guard configured to be coupled to a rear end of a trailer, comprising: a bumper support member configured to be coupled to the rear end of the trailer; and a horizontal bumper mounted at a lower end of the bumper support member, wherein the bumper support member includes a hollow, generally triangular prism member, wherein the triangular hollow prism member includes first and second generally triangle-shaped faces, a vertical member, a horizontal member, and an angled member, and wherein the vertical, horizontal and angled members are each positioned between and coupled to outer edges of the first and second triangular-shaped faces.
 2. The rear impact guard of claim 1, wherein each triangular-shaped face includes a first bottom edge and the vertical member includes a second bottom edge generally perpendicular to the first bottom edge, and wherein a top surface of the horizontal bumper is coupled to the first and second bottom edges of the triangular hollow prism member.
 3. The rear impact guard of claim 1, wherein each triangular-shaped face includes a generally triangular-shaped aperture, and wherein the horizontal member and the angled member each include an aperture.
 4. The rear impact guard of claim 1, wherein the vertical member extends vertically above the horizontal member.
 5. The rear impact guard of claim 1, wherein a first distance between a forward-most portion of each triangular-shaped face is less than a second distance between outer edges of the horizontal member.
 6. The rear impact guard of claim 1, wherein a bottom edge of the angled member is coupled to a front wall of the horizontal bumper and wherein the horizontal bumper is generally tube-shaped.
 7. The rear impact guard of claim 1, wherein an angle between the vertical member and each triangular-shaped face is less than 90 degrees.
 8. The rear impact guard of claim 7, wherein the angle is approximately 87 degrees.
 9. The rear impact guard of claim 1, wherein the first triangular-shaped face, the second triangular-shaped face, and the vertical member cooperate to define a one-piece component.
 10. The rear impact guard of claim 9, wherein the horizontal member and the angled member cooperate to define a one-piece component.
 11. The rear impact guard of claim 1, wherein the bumper support member is a first bumper support member, and wherein the rear impact guard further includes a second bumper support member spaced-apart from the first bumper support member.
 12. The rear impact guard of claim 11, further comprising a third bumper support member.
 13. The rear impact guard of claim 12, further comprising a floor assembly, a first support base associated with the first bumper support member, a second support base associated with the second bumper support member, and a third support base associated with the third bumper support member, and wherein each of the support bases is positioned between its respective bumper support member and the floor assembly.
 14. The rear impact guard of claim 13, further comprising a fourth bumper support member and a fourth support base associated with the fourth bumper support member, and wherein the first and second bumper support members are positioned to the left of a longitudinal axis of the trailer and the third and fourth bumper support members are positioned to the right of a longitudinal axis of the trailer when viewed from the rear.
 15. The rear impact guard of claim 14, wherein the floor assembly includes a pair of spaced apart slide rails extending generally perpendicular to and forwardly away from the bumper, and a plurality of spaced apart cross members positioned over and generally perpendicular to the pair of slide rails, and wherein the first support base and the fourth support base each include a cover, the first and fourth bumper support members and associated first and fourth support bases being positioned outboard of the slide rails, and wherein the second and third support bases include a cutout, each cutouts being positioned below the associated slide rail.
 16. The rear impact guard of claim 15, wherein first and fourth support bases comprise a first continuous member having a first lower surface including at one end a generally upstanding first front arm and at an opposing end a first rear arm extending at an angle generally upwardly and away from the first lower surface and wherein in the cover is an upside down U-shaped cover positioned between the first front arm and the first rear arm downwardly toward the first lower surface; and wherein the second and third support bases comprise a second continuous member having a second lower surface including at one end a generally upstanding second front arm and at an opposing end a second rear arm extending at an angle generally upwardly and away from the second lower surface, the second rear arm including the cutout.
 17. A rear impact guard configured to be coupled to a rear end of a trailer, comprising: a first bumper support member configured to be coupled to the rear end of the trailer; a second bumper support member configured to be coupled to the rear end of the trailer; a third bumper support member configured to be coupled to the rear end of the trailer; a fourth bumper support member configured to be coupled to the rear end of the trailer; a horizontal bumper mounted at a lower end of the bumper support members; a floor assembly including: a pair of spaced apart slide rails extending generally perpendicular to and forwardly away from the bumper, and a plurality of spaced apart cross members positioned over and generally perpendicular to the pair of slide rails; a first support base associated with the first bumper support member; a second support base associated with the second bumper support member; a third support base associated with the third bumper support member; a fourth support base associated with the fourth bumper support member; wherein the bumper support members are spaced-apart from each other, wherein each bumper support member includes a hollow, generally triangular prism member, wherein each of the support bases is positioned between its respective bumper support member and the floor assembly, wherein the first and second bumper support members are positioned to the left of a longitudinal axis of the trailer and the third and fourth bumper support members are positioned to the right of the longitudinal axis of the trailer when viewed from the rear, wherein the first support base and the fourth support base each include a cover, the first and fourth bumper support members and associated first and fourth support bases being positioned outboard of the slide rails, and wherein the second support base and the third support base each include a cutout, each cutout being positioned below the associated slide rail.
 18. A rear impact guard configured to be coupled to a rear end of a trailer, comprising: a bumper support member configured to be coupled to the rear end of the trailer; and a horizontal bumper mounted at a lower end of the bumper support member, wherein the bumper support member includes a hollow, generally triangular prism member, wherein the bumper support member includes a first face, a second face spaced-apart from the first face, and a vertical member positioned between and coupled to the first and second faces, wherein a lower edge of the vertical member and a lower edge of each of the first and second faces is coupled to the horizontal bumper, wherein the first face and the second are angled relative to each other, wherein a first end of each of the first and second faces is coupled to the vertical member and the first ends are spaced-apart from each other a first distance, wherein a second end of each of the first and second faces are spaced-apart from each other a second distance smaller than the first distance, and wherein the bumper support member further includes a generally horizontal member coupled to the vertical member and coupled to and positioned between the first and second faces.
 19. A rear impact guard configured to be coupled to a rear end of a trailer, comprising: a bumper support member configured to be coupled to the rear end of the trailer; a horizontal bumper mounted at a lower end of the bumper support member; and a gusset coupled to the horizontal bumper and an outer end of the bumper support member, wherein the gusset is generally triangular in shape, and wherein the bumper support member includes a hollow, generally triangular prism member.
 20. The rear impact guard of claim 19, wherein the gusset includes a top edge that is generally Z-shaped, wherein a length of the bottom edge of the gusset is shorter than a length of the top edge of the gusset, wherein the gusset includes a triangular wall, a middle wall at a 90 degree angle to the triangular wall, and an end wall at a 90 degree angle to the middle wall such that the end wall and the triangular wall are parallel to each other, wherein the end wall is a parallelogram, wherein the gusset includes a leg configured to extend downwardly over and be coupled to a front wall of the horizontal bumper, wherein a bottom edge of the leg is positioned approximately mid-way along a height of the front wall of the horizontal bumper, wherein the triangular wall is a right-sided triangle and a vertical, side edge of the triangular wall is coupled to the bumper support member and a bottom edge of the triangular wall is coupled to the horizontal bumper, further comprising a gusset attachment coupled to a top edge of the gusset and the bumper support member, wherein the gusset attachment is planar, further comprising a first cross-brace coupled to the bumper support member and the gusset, wherein the first cross-brace extends diagonally at an angle across a forward-facing side of the bumper support member and the gusset, further comprising a second cross-brace coupled to the bumper support member and the gusset, wherein the second cross-brace extends diagonally at an angle across a forward-facing side of the bumper support member and the gusset, wherein the second-cross member is parallel to and spaced-apart from the first cross-brace, wherein the first cross-brace is generally V-shaped in cross-section, and wherein the second cross-brace is generally V-shaped in cross-section. 